Instruction Manual 3024S Diaphragm Actuator

D102625X012 April 2018

Design 3024S Diaphragm Actuator - OBS Valve

Contents
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Safety Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Inspection and Maintenance Schedules . . . . . . . . . . . 2
Parts Ordering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Latest Published Instruction Manual . . . . . . . . . . . . . . 5

Introduction
The product covered in this document is no longer in production. This document, which includes the latest published
version of the instruction manual, is made available to provide updates of newer safety procedures. Be sure to follow
the safety procedures in this supplement as well as the specific instructions in the included instruction manual.

Part numbers in the included instruction manual should not be relied on to order replacement parts. For replacement
parts, contact your Emerson sales office or Local Business Partner.

For more than 20 years, Fisher products have been manufactured with asbestos‐free components. The included
manual might mention asbestos containing parts. Since 1988, any gasket or packing which may have contained some
asbestos, has been replaced by a suitable non‐asbestos material. Replacement parts in other materials are available
from your sales office.

Safety Instructions
Please read these safety warnings, cautions, and instructions carefully before using the product.

These instructions cannot cover every installation and situation. Do not install, operate, or maintain this product
without being fully trained and qualified in valve, actuator and accessory installation, operation and maintenance. To
avoid personal injury or property damage it is important to carefully read, understand, and follow all of the contents of
this manual, including all safety cautions and warnings. If you have any questions about these instructions, contact
your Emerson sales office or Local Business Partner before proceeding.

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3024S Diaphragm Actuator Instruction Manual
April 2018 D102625X012

Specifications
This product was intended for a specific range of service conditions‐‐pressure, pressure drop, process and ambient
temperature, temperature variations, process fluid, and possibly other specifications. Do not expose the product to
service conditions or variables other than those for which the product was intended. If you are not sure what these
conditions or variables are, contact your Emerson sales office or Local Business Partner for assistance. Provide the
product serial number and all other pertinent information that you have available.

Inspection and Maintenance Schedules

All products must be inspected periodically and maintained as needed. The schedule for inspection can only be
determined based on the severity of your service conditions. Your installation might also be subject to inspection
schedules set by applicable governmental codes and regulations, industry standards, company standards, or plant
standards.

In order to avoid increasing dust explosion risk, periodically clean dust deposits from all equipment.

When equipment is installed in a hazardous area location (potentially explosive atmosphere), prevent sparks by proper
tool selection and avoiding other types of impact energy. Control Valve surface temperature is dependent upon
process operating conditions.

WARNING
Control valve surface temperature is dependent upon process operating conditions. Personal injury or property damage,
caused by fire or explosion, can result if the valve body surface temperature exceeds the acceptable temperature for the
hazardous area classification. To avoid an increase of instrumentation and/or accessory surface temperature due to process
operating conditions, ensure adequate ventilation, shielding, or insulation of control valve components installed in a
potentially hazardous or explosive atmosphere.

Parts Ordering
Whenever ordering parts for older products, always specify the serial number of the product and provide all other
pertinent information that you can, such as product size, part material, age of the product, and general service
conditions. If you have modified the product since it was originally purchased, include that information with your
request.

WARNING
Use only genuine Fisher replacement parts. Components that are not supplied by Emerson Automation Solutions should
not, under any circumstances, be used in any Fisher product, because they may void your warranty, might adversely affect
the performance of the product, and could cause personal injury and property damage.

2
Instruction Manual 3024S Diaphragm Actuator
D102625X012 April 2018

Installation
WARNING
D Personal injury or equipment damage caused by sudden release of pressure or bursting of parts may result if the valve
assembly is installed where service conditions could exceed the limits given in the applicable product literature, the
limits on the appropriate nameplates, or the mating pipe flange rating. Use pressure‐relieving devices as required by
government or relevant industry codes and good engineering practices. If you cannot determine the ratings and limits
for this product, contact your Emerson sales office or Local Business Partner before proceeding.
D To avoid personal injury, always wear protective gloves, clothing, and eyewear when performing any installation
operations.
D If hoisting the valve, use a nylon sling to protect the surfaces. Carefully position the sling to prevent damage to the
actuator tubing and any accessories. Also, take care to prevent people from being injured in case the hoist or rigging
might slip. Be sure to use adequately sized hoists and chains or slings to handle the valve.
D Personal injury could result from packing leakage. Valve packing was tightened before shipment; however, the packing
might require some readjustment to meet specific service conditions.
D Many rotary shaft valves are not necessarily grounded to the pipeline when installed in a flammable, hazardous, oxygen
service, or explosive atmospheres. An explosion is possible, due to the discharge of static electricity from the valve
components. To avoid personal injury or property damage, make sure that the valve is grounded to the pipeline before
placing the control valve assembly into service. Use and maintain alternate shaft‐to‐body bonding, such as a
shaft‐to‐body bonding strap assembly.
D Rotary shaft valves are designed and intended for installation between flanges. Personal injury or property damage may
result from improper installation. To avoid personal injury or property damage caused by the sudden release of
pressure or bursting of parts, do not use or install rotary shaft valves (including single lug constructions) for dead‐end
service.
D Check with your process or safety engineer for any additional measures that must be taken to protect against process
media.
D If installing into an existing application, also refer to the WARNING in the Maintenance section.
D When ordered, the valve configuration and construction materials were selected to meet particular pressure,
temperature, pressure drop, and controlled fluid conditions. Responsibility for the safety of process media and
compatibility of valve materials with process media rests solely with the purchaser and end‐user. To avoid possible
personal injury and because some valve/trim material combinations are limited in their pressure drop and temperature
ranges, do not apply any other conditions to the valve without first contacting your Emerson sales office or Local
Business Partner.

CAUTION

D When ordered, the valve configuration and construction materials are generally selected to meet particular pressure,
temperature, pressure drop and controlled fluid conditions. Since some body/trim material combinations are limited in
their pressure drop and temperature ranges, do not apply any other conditions to the valve without first contacting
your Emerson sales office or Local Business Partner.
D Ensure that the valve and adjacent pipelines are free of foreign material that could damage the valve seating surfaces.

3
3024S Diaphragm Actuator Instruction Manual
April 2018 D102625X012

Maintenance
WARNING
Avoid personal injury or property damage from sudden release of process pressure or bursting of parts. Before performing
any maintenance operations:
D Always wear protective gloves, clothing, and eyewear.
D Disconnect any operating lines providing air pressure, electric power, or a control signal to the actuator. Be sure the
actuator cannot suddenly open or close the valve.
D Use bypass valves or completely shut off the process to isolate the valve from process pressure.
D Do not remove the actuator while the valve is pressurized.
D Relieve process pressure from both sides of the valve. Drain the process media from both sides of the valve.
D  Vent the pneumatic actuator loading pressure and relieve any actuator spring pre‐compression.
D Use lock‐out procedures to be sure that the above measures stay in effect while you work on the equipment.
D The valve packing box might contain process fluids that are pressurized, even when the valve has been removed from the
pipeline. Process fluids might spray out under pressure when removing the packing hardware or packing rings, or when
loosening the packing box pipe plug. Cautiously remove parts so that fluid escapes slowly and safely.
D Many valve parts that are moving can injure you by pinching, cutting, or shearing. To help prevent such injury, stay
clear of any moving part.
D Never apply pressure to a partially assembled valve.
D To avoid personal injury or property damage caused by uncontrolled movement of a valve bonnet, loosen the bonnet by
following these instructions: Do not remove a stuck bonnet by pulling on it with equipment that can stretch or store
energy in any other manner. The sudden release of stored energy can cause uncontrolled movement of the bonnet.
Loosen bonnet nuts approximately 3 mm (0.125 inch). Then loosen the body‐to‐bonnet gasketed joint by either rocking
the bonnet or prying between the bonnet and body. Work the prying tool around the bonnet until the bonnet loosens.
If no fluid leaks from the joint, proceed with bonnet removal.
D As you remove parts, such as valve shafts, other parts, such as disks can fall from the valve body or suddenly move to
another position in the valve. To avoid injury from falling or moving parts, be sure to support parts and be sure they are
in a stable position as you disassemble the valve.
D Personal injury could result from packing leakage. Do not scratch the drive shaft or packing box wall while removing
packing parts.
D Check with your process or safety engineer for any additional measures that must be taken to protect against process
media.

Neither Emerson, Emerson Automation Solutions, nor any of their affiliated entities assumes responsibility for the selection, use or maintenance
of any product. Responsibility for proper selection, use, and maintenance of any product remains solely with the purchaser and end user.
Fisher is a mark owned by one of the companies in the Emerson Automation Solutions business unit of Emerson Electric Co. Emerson Automation Solutions,
Emerson, and the Emerson logo are trademarks and service marks of Emerson Electric Co. All other marks are the property of their respective owners.

The contents of this publication are presented for informational purposes only, and while every effort has been made to ensure their accuracy, they are not
to be construed as warranties or guarantees, express or implied, regarding the products or services described herein or their use or applicability. All sales are
governed by our terms and conditions, which are available upon request. We reserve the right to modify or improve the designs or specifications of such
products at any time without notice.
Emerson Automation Solutions
Marshalltown, Iowa 50158 USA
Sorocaba, 18087 Brazil
Cernay, 68700 France
Dubai, United Arab Emirates
Singapore 128461 Singapore

www.Fisher.com

4E 2018 Fisher Controls International LLC. All rights reserved.

 Instruction Manual
Form 5421
June 1999 Design 3024S Actuator

Design 3024S Diaphragm Actuator

Contents
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Scope of Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Actuator Mounting . . . . . . . . . . . . . . . . . . . . . . . . 4
Travel Adjustments . . . . . . . . . . . . . . . . . . . . . . . 5
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Changing Actuator Action . . . . . . . . . . . . . . . . . . 7
Side Mounted Handwheel . . . . . . . . . . . . . . . . . 7
Adjustable Travel Stops . . . . . . . . . . . . . . . . . . . 9
Parts Ordering . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Parts List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

Introduction
W6681B

Scope of Manual
This instruction manual provides information on
installation, adjustment, maintenance and parts
ordering for the Type GA 1.21, GA 1.31 and GA 1.41
actuators.
Description
The direct acting (extends stem) actuator (figure 6
and 9) and the reverse acting (retracts stem)
actuators (figure 7 and 10) are spring-opposed
pneumatic diaphragm actuators that provide
throttling or on-off operation of sliding-stem control
valves. The Type 3024S ATC actuator springs are
Figure 1. Type 3024S Actuator with Design 1018S Valve.
located under the diaphragm plate, and they fully
retract the actuator stem for fail action upon loss of
diaphragm casing pressure. The Type 3024S ATO
actuator springs are located on top of the diaphragm
plate, and they fully extend the actuator stem upon
loss of diaphragm casing pressure.
Only personnel qualified through training or
experience should install, operate and maintain Type
3024S actuators.

D102625X012

www.Fisher.com
 Instruction Manual
Form 5421
Design 3024S Actuator June 1999

Table 1. Specifications

Actuator Sizes Material Temperature Capabilities

GA1.21 With Nitrile Diaphragm and Steel studs and nuts :
GA 1.31 -40_C to +90_C (-40_F to 194_F)
GA 1.41
Signal Connections
Standard: G1/4 inch Withworth female thread
Maximum Actuator Travels (ISO 7-1/BS 21/DIN2999)
Size GA 1.21 and GA 1.31: 16 mm (0.63 inch)
Actuator Stem Diameters
Size GA 1.31 and GA 1.41 : 32 mm (1.26 inch)
Size GA 1.21 and GA 1.31: 12mm (0.472 inch)
Size GA 1.41: 16mm (0.630 inch)
Standard Operating Pressure Range
See table 2a (ATC) and 2b (ATO) Acceptable Valve Stem Threads
Size GA 1.21 and GA 1.31: M12 X 1.75 (2 1/8”
yoke boss & 16mm travel)
Maximum Operating Pressure Size GA 1.31 and GA 1.41: M16 X 2 (2 13/16”
See table 2a (ATC) and 2b (ATO) yoke boss & 32mm travel)

Approximate Weights
Maximum Output Thrust Size GA 1.21: 7.1 kg (15.6 pounds)
(Maximum Actuator Stem Force) Size GA 1.31: 16.5 kg (36.4 pounds)
See table 2a (ATC) and 2b (ATO) Size GA 1.41: 33.5 kg (73.9 pounds)

shown in table 1. Some of the specifications for a

given actuator assembly as it originally comes from
the factory are stamped on a nameplate (figure 2.)
Specifications attached to the actuator.
Specifications for the Type 3024S actuators are

E0798

Figure 2. Type 3024S Actuator Nameplate

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Instruction Manual
Form 5421
June 1999 Design 3024S Actuator
Table 2a. Additional Specifications, Action - Air to Close (ATC)
Maximum Output Thrust
Spring Set Maximum Operating
Travel Range (Maximum Actuator Stem
Type No. / Qty/ Pressure to Diaphragm
Force)(1)
Color
Inch mm Psig Bar Psig Bar Lb N
218 / 5 / R 0.63 16 19 − 33 1.3 − 2.3 87 6 461 2054
GA 1.21
218 / 7 / G 0.63 16 23 − 44 1.6 − 3.0 87 6 568 2528
219 / 3 / B 0.63 16 3 − 15 0.2 − 1.0 87 6 214 954
211 / 6 / R 0.63 16 6 − 15 0.4 − 1.0 87 6 429 1908
212 / 5 / G 0.63 16 22 − 35 1.5 − 2.4 87 6 1608 7155
GA 1.31 212 / 7 / G 0.63 16 29 − 46 2.0 − 3.2 87 6 2144 9540
211 / 3 / R 1.26 32 --- 0.2 − 1.0 87 6 220 978
212 / 5 / G 1.26 32 10 − 33 0.7 − 2.3 87 6 769 3423
212 / 7 / G 1.26 32 13 − 46 0.9 − 3.2 87 6 989 4401
220 / 4 / R 1.26 32 --- 0.2 − 1.0 87 6 391 1742
221 / 8 / G 1.26 32 10 − 26 0.7 − 2.3 87 6 1370 6097
GA 1.41 221 / 10 G 1.26 32 15 − 35 1.0 − 2.4 87 6 1958 8710
221 / 12 / G 1.26 32 18 − 41 1.2 − 2.8 87 6 2349 10452
221 / 14 / G 1.26 32 21 − 46 1.4 − 3.2 87 6 2741 12194
1. Based on zero operating pressure to diaphragm for Type 3024S actuator and valve travel 0%. This does not consider limitations to valve, such as stem buckling loads.

Table 2b. Additional Specifications, Action - Air to Open (ATO)

Maximum Output Thrust
Spring Set Maximum Operating
Travel Range (Maximum Actuator Stem
Type No. / Qty/ Pressure to Diaphragm
Force)(1)
Color
Inch mm Psig Bar Psig Bar Lb N
217 / 3 / R 0.63 16 3 − 15 0.2 − 1.0 87 6 1528 6800
GA 1.21 218 / 5 / G 0.63 16 19 − 34 1.3 − 2.3 87 6 1131 5032
218 / 7 / G 0.63 16 23 − 44 1.6 − 3.0 87 6 917 4080
219 / 3 / B 0.63 16 3 − 15 3 − 15 87 6 4395 19550
211 / 6 / R 0.63 16 6 − 15 6 − 15 87 6 4395 19550
212 / 5 / G 0.63 16 22 − 35 22 − 35 87 6 3164 14076
GA 1.31 212 / 7 / G 0.63 16 29 − 46 29 − 46 87 6 2461 10948
211 / 3 / R 1.26 32 3 − 15 0.2 − 1.0 87 6 4519 20100
212 / 5 / G 1.26 32 10 − 33 0.7 − 2.3 87 6 3344 14874
212 / 7 / G 1.26 32 13 − 46 0.9 − 3.2 87 6 2531 11256
220 / 4 / R 1.26 32 3 − 15 0.2 − 1.0 87 6 8161 36300
221 / 8 / G 1.26 32 10 − 26 0.7 − 2.3 87 6 6855 30492
GA 1.41 221 / 10 G 1.26 32 15 − 35 1.0 − 2.4 87 6 5876 26136
221 / 12 / G 1.26 32 18 − 41 1.2 − 2.8 87 6 5223 23232
221 / 14 / G 1.26 32 21 − 46 1.4 − 3.2 87 6 4570 20338
1. Based on zero operating pressure to diaphragm for Type 3024S actuator and valve travel 0%. This does not consider limitations to valve, such as stem buckling loads.

Installation A Type 3024S diaphragm actuator is normally

shipped mounted on a valve. Refer to the
appropriate valve instruction manual when installing
WARNING the valve in the pipeline. If the actuator is shipped
separately or if it is necessary to mount the actuator
Personal injury or equipment damage on the valve, perform the Actuator Mounting
caused by sudden release of pressure procedure given below. For information on mounting
may result if the valve assembly is the positioner, refer to the positioner instruction
installed where service conditions manual.
could exceed the limits given in table 1
and 2 or the appropriate nameplates.
To avoid such injury or damage,
provide a relief valve for overpressure
protection as required by accepted
industry or local, state and federal
codes and good engineering practices.

3

Design 3024S Actuator
CAUTION
The Type 3024S actuators are
designed to mount on
push-down-to-close valves. Do not
mount these actuators on any other
type of valve without first contacting
the Fisher sales office.
Actuator Mounting
The following procedure describes how to mount a
Type 3024S actuator on a push-down-to-close valve
so that the actuator stem and valve stem thread
engagement allows full travel and proper shutoff.
Refer to figure 5 for actuator dimensions. Key
numbers referenced in the following steps are shown
in figures 6, 7, 9 & 10.
1. Thread the stem hex nut (key 54/52) first and
then the connector (key 50) onto the valve stem and
run them down.
2. Push the valve stem down until the valve plug is
fully closed.
3. Carefully place the actuator with the flange (key
45) on the valve bonnet.
WARNING
When moving the actuator stem with
diaphragm loading pressure use
caution to keep hands and tools out of
the actuator stem travel path. Personal
injury and/or property damage is
possible if something is caught
between the actuator stem and other
control valve assembly parts.
CAUTION
Be sure that the length of the actuator
stem or the valve stem in the
connector (key 50 or 53) is equal to or
greater than the diameter of that stem.
In the following procedure, do not
rotate the valve plug while it is seated.
This may damage the seating surface
and thereby allow excessive leakage.
Also, during adjustment, use tools
carefully to avoid damaging the valve
4
Instruction Manual
Form 5421
June 1999
stem. A damaged stem could cut the
packing and allow leakage.
4. Perform one of the following procedures as
appropriate:
For a Type 3024S Air-To-Close actuator with a
push-down-to-close valve:
a. Tighten the valve bonnet lock nut.
b. Adjust the travel: rotate the connector halves
(key 53 and 50) so that the distance between
them (with the valve on the seat and the travel
indicator-key 51 between the connectors) is equal
to the valve travel.
c. Pressurise the actuator slowly and adjust the
stem connector half (key 50) so the connecting
bolts will line up.
d. Tighten all bolts (key 55/56) and nuts (key
56/57).
e. Apply bench set pressure to the top of the
diaphragm and check the valve stem travel.
f. Tighten the valve stem hex nut (key 54/52)
against the stem connector (key 50).
For a Type 3024S Air-To-Open actuator with a
push-down-to-close valve:
a. Apply approximately 0.5 bar above the highest
setting of the bench set pressure to the bottom of
the diaphragm. This positions the actuator stem
(key 8) at the highest point.
b. Tighten the valve bonnet lock nut.
c. Adjust the travel: rotate the connector halves
(key 53 and 50) so that the distance between
them (with the plug on the seat and the travel
indicator key 51 between the connectors) is equal
to the valve travel.
d. Exhaust the actuator slowly and adjust the
stem connector half (key 50) so the connecting
bolts will line up.
e. Completely exhaust the actuator and tighten
all bolts (key 55/56) and nuts (key 56/57).
f. Apply approximately 0.5 bar above the highest
bench set pressure to the top of the diaphragm
and check the valve stem travel.
g. Tighten the valve stem hex nut (key 54/52)
against the stem connector (key 50).
Instruction Manual
Form 5421
June 1999
For a Type 3024S Air-To-Open & Air-To-Close
actuators:
5. Cycle the actuator several times to check for
proper operation.
6. Adjust the travel indicator scale (key 26) up or
down to correspond with the travel indicator.
Travel Adjustments
Although making travel adjustments should not be
necessary if previous section on Actuator Mounting
has been followed, use the following procedure
when the actuator travel is different from that
stamped on the actuator nameplate (figure 2).
When adjusting the travel of a push-down-to-close
valve air-to-open actuator combination, slightly
pressurise the actuator. This moves the valve plug
off the seat, reducing the chance of damaging the
valve plug or seat during adjustment.
1. Back off the stem hex nut (key 54/52) from the
valve stem connector, and slightly loosen both/all 4
cap screws (key 55/56) from the connectors.
2. Screw the connector (key 50) clockwise (to
lengthen travel) or counter-clockwise (to shorten
travel).
3. Tighten the stem connector cap screw (key
55/56).
4. Cycle the actuator to check for the specified
travel. If the travel is not equal to the specified travel,
adjust and check it until it is correct. Tighten the
stem hex nut (key 54/52) against the stem
connector.
Maintenance
Actuator parts are subject to normal wear and must
be inspected and replaced as necessary. The
frequency of inspection and replacement depends
upon the severity of the service conditions. Due to
the care Fisher takes in meeting manufacturing
requirements (heat treating, dimensional tolerances,
etc.), use only replacement parts manufactured or
furnished by Fisher.
This section describes how the actuator can be
completely disassembled and assembled. When
inspection or repairs are required, disassemble only
Design 3024S Actuator
those parts necessary to accomplish the job; then
start the assembly at the appropriate step.
Key numbers refer to figure 6 for a Size 1.21/1.31
Air-To-Close actuator, to figure 7 for a 1.21/1.31
Air-To-Open actuator, figure 9 for a Size 1.41
Air-To-Close actuator, to figure 10 for a 1.41
Air-To-Open actuator.
Disassembly
WARNING
Avoid personal injury or damage to
property from sudden release of
pressure, uncontrolled process fluid,
or precompressed spring force. Before
starting disassembly:
D Isolate the valve from the
process,
D Release process pressure,
D Vent all internal pressure from the
actuator,
D Release all spring preloading
force,
D Use lock-out procedures to be
sure that the above measures stay in
effect while you work on the
equipment.
1. For complete disassembly, the positioner and all
accessories (if attached) must be removed from the
actuator. Follow the appropriate removal procedures
in the instruction manuals supplied with the
positioner and accessories.
2. Bypass the control valve. Reduce the loading
pressure to atmospheric, and for a bottom-loaded
Type 3024S Air-To-Open actuator, remove the
tubing or piping from the connection in the lower
diaphragm casing (key 1).
For a top-loaded Type 3024S Air-To-Close actuator,
remove the piping or tubing from the connection in
the upper diaphragm casing (key 16).
3. Slightly loosen all diaphragm casing cap screws
(key 19 and 21). Remove the plastic hose (key 22).
Unscrew the short and long diaphragm casing cap
screws and nuts (key 19, 20 and 21) alternately, until
only the long casing cap screws (key 21) remain
engaged. Then allow the remaining spring
compression to be slowly and evenly released by
alternately unscrewing the long casing cap screws.
5

Design 3024S Actuator
4. When removing the diaphragm and actuator
springs perform one of the following procedures as
appropriate:
For a Type 3024S Air-To-Open actuator
(figure 7 & 10):
a. Lift off the upper diaphragm casing (key 16)
and remove the springs (key 15).
b. Using a strap wrench or soft-jawed vice and
the actuator stem (key 8), remove the hex nut
(key 14).
c. Remove the diaphragm plate (key 13),
diaphragm (key 11), O-Ring (key 12), pressure
plate (key 10) and the ring halves (key 9).
For a Type 3024S Air-To-Close actuator (figure 6 &
9) :
a. Lift off the upper diaphragm casing (key 16).
b. Using a strap wrench or soft-jawed vice and
the actuator stem (key 8), remove the hex nut
(key 14).
c. Remove the pressure plate (key 10), O-Ring
(key 12), diaphragm (key 11) , diaphragm plate
(key 13) and the ring halves (key 9).
d. Remove the springs (key 15).
1. Carefully slide the actuator stem (key 8) out the
bottom of the lower diaphragm casing (key 1) and
set it on a protective surface to prevent damage to
the O-ring sealing surface.
2. Remove the bellow (key 31), if used.
3. Unscrew the cheese head screws (key 7), then
remove the bushing (key 6).
4. With the actuator disassembled, inspect all parts
for excessive wear and replace as necessary.
Assembly
This procedure assumes that the actuator is
completely disassembled. If it is not, start the
instructions at the appropriate step.
For a Type 3024S Air-To-Open & Air-To-Close
actuator :
1. Before starting assembly, apply Lubriplate
MAG-1 lubricant or equivalent to the O-ring (in the
bushing key 6 and key 12). Install the new bushing
(key 6) and assemble with the cheese head screws
6
Instruction Manual
Form 5421
June 1999
(key 7) onto the lower diaphragm casing (key 1).
Use a torque of 0.4 NSm (0.25 lbfSft)
2. Carefully slide the actuator stem (key 8) down
through the bushing (key 6) .
3. When installing the diaphragm and actuator
springs perform one of the following procedures as
appropriate:
For a Type 3024S Air-To-Open:
a. Assemble the ring halves (key 9), pressure
plate (key 10), O-Ring (Key 12), diaphragm (Key
11) and diaphragm plate (key 13) as shown in
figure 7 or 10.
b. Apply Loctite 271 or equivalent to the actuator
stem travel stop thread and tighten the travel stop
as follows: Sizes GA 1.21/1.31 tighten to 37 NSm
(28 lbfSft), size GA 1.41 tighten to 90 NSm (66
lbfSft).
c. Position the actuator springs (key 15)
symmetrical on the diaphragm plate (key 13) as
shown in figure 3.
For a Type 3024S Air-To-Close:
a. Assemble the ring halves (key 9), pressure
plate (key 10), O-Ring (Key 12), diaphragm (Key
11) and diaphragm plate (key 13) as shown in
figure 6 or 9.
b. Apply Loctite or equivalent to the actuator
stem travel stop thread and tighten the travel stop
as follows: Sizes GA 1.21/1.31 tighten to 37 NSm
(28 lbfSft), size GA 1.41 tighten to 90 NSm (66
lbfSft).
c. Position the actuator springs (key 15)
symmetrical on the diaphragm plate (key 13) as
shown in figure 3.
CAUTION
Overtightening the diaphragm cap
screws and nuts can damage the
diaphragm. Do not exceed a torque of
11 NSm (8 lbfSft) for Size GA 1.21 and
16 NSm (12 lbSft) for sizes GA 1.31 &
1.41.
Instruction Manual
Form 5421
June 1999
For a Type 3024S Air-To-Close & Air-to-Open:
4. Install the upper diaphragm casing (key 16) using
the long cap screws (key 21) and hex nuts (key 20)
first. Then secure with cap-screws (key 19) and hex
nuts (key 20). Be sure the supply connection is
located directly above the vent in the lower
diaphragm. Fit the plastic hose (key 22) over the cap
screws (key 21).
Note
Be sure to use the long cap screws
(key 21), first installing them on the
opposite sides of the diaphragm
casing. Tighten them evenly, using a
crisscross pattern to ensure a proper
seal.
5. Mount the actuator on the valve in accordance
with the Installation procedures.
Changing Actuator Action
The Actuator can be changed from a Type 3024S
ATO to a 3024 ATC or vice versa by removing the
pressure plate, diaphragm, O-ring, diaphragm plate,
hex nut, springs, spring locator, self tapping screws
and vent assembly (key 10, 11, 12, 13, 14, 15, 17,
18 and 23) and installing them for appropriate action.
See figures 6, 7, 9 and 10. For hex nut or travel stop
(key 14) and pressure plate (key 10) selection refer
to parts list. Follow the procedures in the Actuator
Mounting section and the Travel Adjustment section
for connection to the valve.
Side-Mounted Handwheel
A side-mounted handwheel assembly (figure 4) is
usually used as a manual operator. When mounted
on an ATC type 3024S actuator, turning the
handwheel clockwise always closes the valve. When
mounted on an ATO actuator, turning the handwheel
clockwise always opens the valve, A lever (key 49,
figure 12) on the handwheel assembly opens or
closes the valve by moving the valve stem.
Instructions are given below for complete
disassembly and assembly. Perform the
disassembly only as far as necessary to accomplish
the required maintenance; then begin the assembly
at the appropriate step.
Design 3024S Actuator
Refer to figure 12 for key numbers.
Disassembly
1. If desired, the handwheel assembly can be
removed from the actuator leg post. To do this,
remove the hex nuts (key 62) and back plates (key
64) from the U-bolts (key 61) that hold the assembly
to the leg-post.
2. Loosen the lock (key 63) that secures the drive
screw assembly (key 51).
3. Remove the retaining ring (key 58) and screw out
the drive screw assembly (key 51).
4. Remove the retainer ring (key 56) and drive out
the pivot pin (key 52).
5. Remove the bushings (key 55) from the body
(key 48).
6. There is a cap screw (key 59), hex nut (key 60),
and spacer (key 53) that hold the two levers (key 49)
together. Remove the cap screw and hex nut and
the two levers can be separated in order to remove
the operating nut (key 50).
Assembly
1. Assemble the operating nut (key 50), the two
levers (key 49), and the spacer (key 53) using the
cap screw (key 59) and hex nut (key 60).
2. Install the bushings (key 55) in the body (key 48).
3. Attach the levers (key 49) to the body (key 48)
using the pivot pin (key 52) and the retaining ring
(key 56).
4. Apply lubricant Lubriplate MAG-1 or equivalent to
the drive screw assembly (key 51) and screw it on to
the operating nut (key 50).
5. Install the retaining ring (key 58. to secure the
collar to the body (key 48).
6. If the handwheel assembly was removed from the
actuator leg posts, position the U-bolts (key 61),
back plate (key 64) and handwheel body (key 48) to
the actuator leg posts as shown in figures 3 & 12.
Tighten the hex nuts (key 62) to 19 NSm (14 lbfSft).
Clearance between the lower diaphragm casing and
the handwheel body are shown in figure 4. With the
actuator fully open the distance between the lower
face of the actuator stem connector and the actuator
flange should be shown in figure 4.
7
 Instruction Manual
Form 5421
Design 3024S Actuator June 1999

E0799

Figure 3. Type 3024S Spring Arrangements.

8
Instruction Manual
Form 5421
June 1999 Design 3024S Actuator

A B
Actuator Size Travel (mm)
Millimeters
GA 1.21 16 15 112
GA 1.31 16 5 112
GA 1.41 32 10 123
Inches
GA 1.21 16 1/2 4−1/2
GA 1.31 32 1/4 4−1/2
GA 1.41 32 1/2 5

A
A

B
B

TYPE 3024S TYPE 3024S

E0800 AIR-TO-CLOSE AIR-TO-OPEN

Figure 4. Type 3024S Actuator Handwheel Mounting (GA 1.21 and 1.31 Only).

Adjustable Travel Stops
The adjustable up travel stop (figure 8) for GA 1.21
and 1.31 actuators limits the actuator stroke in the
upward direction (limits retraction of the actuator
stem).
Loosen the hex nut (key 25) and turn the adjuster
(key 24) clockwise into the diaphragm case to move
the actuator stem downward or counter-clockwise to
allow the actuator stem to move upward. Since the
valve has push-down-to-close action, full opening
can be restricted. Check the actuator travel and then
tighten the hex nut (key 25).
For the GA 1.41 actuator up travel stop key numbers
referenced in the following steps are shown in figure
11.
1. Loosen the head screws (key 8)
2. Unscrew the cap screws and nuts (key 5 and 7)
and remove the cover plate (key 4)
3. Loosen the head screw (key 2) and turn the
bushing (key 3) clockwise into the adjustment nut
(key 1) to allow the actuator stem to move upward or
counter clockwise to shorten the actuator travel.
4. Check the actuator travel and then tighten the
head screw (key 2).
5. Assemble the cover plate (key 4) and tighten the
cap screws and nuts (key 5 and 7).
CAUTION
In the following adjustment
procedures, take care to avoid injury
while positioning components.
6. Adjust the cover plate (key 4) so that there is no
gap between the diaphragm case and the cover
plate.
7. Tighten the head screw (key 8).

9
 Instruction Manual
Form 5421
Design 3024S Actuator June 1999

C
Actuator Travel E F AR
Diameter
Size (mm)
Millimeters
GA 1.21 16 215 360(1)
105
16 315 450
GA 1.31 45
32 315 480
133
GA 1.41 32 420 515
Inches
GA 1.21 16 8.46 14.17
4.13
16 12.40 17.72
GA 1.31 1.77
32 12.40 18.90
5.24
GA 1.41 32 16.54 20.28
1. Without lifting ring.

AR

MATCH LINE FOR VALVE BODY

E0801

Figure 5. Actuator Dimensions (Reverse Acting).

10
Instruction Manual
Form 5421
June 1999 Design 3024S Actuator

Parts Ordering Key

12*
Description
O-Ring, nitrile
Part Number

Size GA 1.21 & 1.31 0409073

Each actuator has a serial number stamped on the
Size GA 1.41 0411736
nameplate (figure 2 and key 34, figure 6, 7 and 10). 13 Diaphragm Plate
Refer to the serial number when ordering Size GA 1.21, aluminium 1136887
replacement parts or when corresponding with your Size GA 1.31, aluminium 2631032
Fisher sales office or sales representative for Size GA 1.41, cast iron 0444987
technical assistance. Also, specify the complete 7 or 14 Hex Nut, steel
11-character part number from the following parts list Size GA 1.21, Travel 16mm
1.3 - 2.3 bar (19 - 34 psig) ATO 0828939
when ordering replacement parts. 1.6 - 3.0 bar (23 - 44 psig) ATO 0828661
0.2 - 1.0 bar (3 - 15 psig) ATC 0476986
1.3 - 2.3 bar (19 - 34 psig) ATC 0476986
1.6 - 3.0 bar (23 - 44 psig) ATC 0828939
Size GA 1.31, Travel 16mm
0.2 - 1.0 bar (3 - 15 psig) ATO 0411108
0.2 - 1.0 bar (3 - 15 psig) ATC 0476986
Parts List 0.4 - 1.0 bar (6 - 15 psig) ATO and ATC 0411108
1.5 - 2.4 bar (22 - 35 psig) ATO 0127515
Actuator 1.5 - 2.4 bar (22 - 35 psig) ATC
2.0 - 3.2 bar (29 - 46 psig) ATO
0411108
0127515
Key Description Part Number 2.0 - 3.2 bar (29 - 46 psig) ATC 0828661
1 Lower Diaphragm Casing, steel Size GA 1.31, Travel 32 mm, ATO and ATC
Size GA 1.21 0410632 0.2 - 1.0 bar (3 - 15 psig) 0476986
Size GA 1.31 0449660 0.7 - 2.3 bar (10 - 33 psig) 0127515
Size GA 1.41 0449687 0.9 - 3.2 bar (13 - 46 psig) 0127515
3* Gasket (2 required) Size GA 1.41, Travel 32 mm
Size GA 1.21 0409081 0.2 - 1.0 bar (3 - 15 psig) ATO and ATC 1768247
Size GA 1.31 & 1.41 0411426 0.7 - 1.8 bar (11-26 psig) ATO 0127531
4 Supporting Ring, steel 0.7 - 1.8 bar (11-26 psig) ATC 1768247
Size GA 1.21 --- 1.0 - 2.4 bar (15-35 psig) ATO and ATC 0127531
Size GA 1.31 & 1.41 (2 required) 0411434 1.2 - 2.8 bar (17-41 psig) ATO and ATC 0127531
5 Leg Post, steel (2 required) 1.4 - 3.2 bar (20-46 psig) ATO and ATC 0127531
Size GA 1.21, Travel 16mm 0409090 15 Spring, steel
Size GA 1.31, Travel 16mm 1066803 Size GA 1.2, Travel 16 mm
Size GA 1.31 & 1.41 , Travel 32mm 2539667 0.2 - 1.0 bar ( 3 - 15 psig) (3 required) 0410853
6* Bushing 1.3 - 2.3 bar (19 - 34 psig) (5 required) 0410861
Size GA 1.21 & 1.31 0409065 1.6 - 3.0 bar (23 - 44 psig) (7 required) 0410861
Size GA 1.41 0411159 Size GA 1.31, Travel 16 mm
7 Cheese Head Screw, 0.2 - 1.0 bar ( 3 - 15 psig) (3 required) 0411086
stainless steel (6 required) 0119512 0.4 - 1.0 bar ( 6 - 15 psig) (6 required) 0409111
8 Actuator Stem, stainless steel 1.5 - 2.4 bar (22 - 35 psig) (5 required) 0410411
Size GA 1.21 0410713 2.0 - 3.2 bar (29 - 46 psig) (7 required) 0410411
Size GA 1.31 0410284 Size GA 1.31, Travel 32 mm
Size GA 1.41 0411752 0.2 - 1.0 bar ( 3 - 15 psig) (3 required) 0409111
9 Ring Half, stainless steel (2 required) 0.7 - 2.3 bar (10 - 33 psig) (5 required) 0410411
Size GA 1.21 & 1.31 0410365 0.9 - 3.2 bar (29 - 46 psig) (7 required) 0410411
Size GA 1.41 0411876 Size GA 1.41, Travel 32 mm
10 Pressure Plate 0.2 - 1.0 bar ( 3 - 15 psig) (4 required) 0411124
Size GA 1.21, aluminium ATO and ATC 1136879 0.7 - 1.8 bar (11 - 26 psig) (8 required) 0411132
Size GA 1.31, steel, Travel 16 mm 1.0 - 2.4 bar (15 - 35 psig) (10 required) 0411132
0.2 - 1.0 bar (3 - 15 psig) ATO and ATC 0410373 1.2 - 2.8 bar (17 - 41 psig) (12 required) 0411132
0.4 - 1.0 bar (6 - 15 psig) ATO and ATC 0410373 1.4 - 3.2 bar (20 - 46 psig) (14 required) 0411132
1.5 - 2.4 bar (22 - 35 psig) ATO 2139839 16 Upper Diaphragm Casing, steel
1.5 - 2.4 bar (22 - 35 psig) ATC 0410373 Size GA 1.21 0410756
2.0 - 3.2 bar (29 - 46 psig) ATO 2139839 Size GA 1.31 0411060
2.0 - 3.2 bar (29 - 46 psig) ATC 0410373 Size GA 1.41 0412007
Size GA 1.31, steel, Travel 32 mm, ATO and ATC 0410373 For adjustable up stop (optional)
Size GA 1.41, steel, ATO and ATC 0411884 Size GA 1.21 0478873
Size GA 1.31 0478865
11* Diaphragm, nitrile 17 Spring Locator, stainless steel
Size GA 1.21 0410705 Size GA 1.21 0411604
Size GA 1.31 0410357 Size GA 1.31 0410322
Size GA 1.41 0411868 Size GA 1.41 0411809

*Recommended spare parts 11

 Instruction Manual
Form 5421
Design 3024S Actuator June 1999

GA 1.21 DOES NOT HAVE LIFTING RING

GA 1.21 DOES NOT HAVE LIFTING RING

E0803

E0802

1 FOR 32 mm TRAVEL, USE KEY 52 HERE INSTEAD OF KEY 54.

Figure 7. Size GA 1.21 and 1.31 Reverse-Acting Actuator

Figure 6. Size GA 1.21 and 1.31 Direct-Acting Actuator (ATC). (ATO).

E0805

E0804

Figure 8. Adjustable Up Travel Stop for Size GA 1.21 and 1.31.

12
Instruction Manual
Form 5421
June 1999 Design 3024S Actuator

E0807

E0806

Figure 9. Size GA 1.41 Direct-Acting Actuator (ATC). Figure 10. Size GA 1.41 Reverse-Acting Actuator (ATO).

TRAVEL STOP (KEY 60)

E0808 E0809

Figure 11. GA 1.41 Adjustable Up Travel Stop

13
 Instruction Manual
Form 5421
Design 3024S Actuator June 1999

Key Description Part Number Key Description Part Number

18 Convex Fillister Head Screw, 51 Travel Indicator 0458180
steel (2 required) 0410403 52 Hex nut, GA 1.31, Travel 32 mm (1 required) 0127531
19 Cap Screw, steel 53 Actuator Stem Connector, steel
Size GA 1.21 (7 required) 0125385 Without Side Mounted Handwheel
Size GA 1.31 (12 required) 0125490 Size GA 1.21, Travel 16 mm ATO and ATC 1594842
Size GA 1.41 (17 required) 0125490 Size GA 1.31, Travel 16 mm
20 Hex Nut, steel 0.2 − 1.0 bar (3 − 15 psig) ATO and ATC 1594842
Size GA 1.21 (10 required) 0127485 0.4 − 1.0 bar (6 − 15 psig) ATO and ATC 1594842
Size GA 1.31 (15 required) 0127493 1.5 − 2.4 bar (22 − 35 psig) ATO 0458120
Size GA 1.41 (20 required) 0127493 1.5 − 2.4 bar (22 − 35 psig) ATC 1594842
21 Hex Cap Screw, steel (3 required) 2.0 − 3.2 bar (29 − 46 psig) ATO 0458120
Size GA 1.21 0467235 2.0 − 3.2 bar (29 − 46 psig) ATC 1594842
Size GA 1.31 0464651 Size GA 1.31, Travel 32 mm, ATO and ATC 0458120
Size GA 1.41 0464643 Size GA 1.41, Travel 32 mm
22 Plastic Hose, PVC (3 required) 0.2 − 1.0 bar (3 − 15 psig) ATO and ATC 0458112
Size GA 1.21 0479748 All except 0.2 − 1.0 bar ATO and ATC 0458139
Size GA 1.31 0479730 With Side Mounted Handwheel
Size GA 1.41 0479721 Size GA 1.21, Travel 16mm ATO and ATC 0319678
23 Vent Assembly, plastic 0410233 Size GA 1.31, Travel 16mm ATO and ATC 1594842
24 Hex Cap Screw, steel 1.21 & 1.31 (optional) 0125628 Size GA 1.31, Travel 32mm ATO and ATC 1594842
25 Hex Nut, steel 1.21 & 1.31 (optional) 0410993
26 Travel Indicator Scale, stainless steel 54 Hex Nut, steel
Size GA 1.21, Travel 16 mm 2492431 Size GA 1.21 & 1.31, Travel 16 mm (2 required) 0127515
Size GA 1.31, Travel 16 mm 2492474 Size GA 1.31, Travel 32 mm (1 required) 0127515
Size GA 1.31, Travel 32 mm 2492466 Size GA 1.41 (2 required) 0127531
27 Nut 10B1272X012 55 Hex Cap Scres, steel (2 required)
28 Screw 19A4786X012 Without Side-Mounted Handwheel 0125512
With Side-Mounted Handwheel 1Q39761F012
30 Hex Nut, steel (2 required) 0127531 56 Hex Nut, steel
31* Bellows 0409154 Size GA 1.21 & 1.31 (2 required) 0127493
33 Warning Label 0444375 Size GA 1.41 (4 required) 0127493
34 Nameplate, stainless steel 2472503 57 Hex Cap Screw, steel (2 required)
35 Tab Washer, stainless steel Size GA 1.41 0125490
Size GA 1.21 1167731 60 Adjustable up travel stop for Size 1.41 (Optional)
Size GA 1.31 & 1.41 1167758 1 Nut, adjustment (1 required) 0625850
45 Actuator flange, steel 2 Cap Screw (1 required) 0119504
2 1/8” Yoke Boss (Travel 16 mm) 2484307 3 Bush 0625876
2 13/16” Yoke Boss (Travel 32 mm) 2539659 4 Cover Plate (2 required) 1607758
50 Valve Stem Connector, steel 5 Cap Screw 0262226
Without Side Mounted Handwheel 6 Washer 0120766
Size GA 1.21, Travel 16 mm, ATO and ATC 0319678 7 Hex nut 0127752
Size GA 1.31, Travel 16 mm 8 Cap screw 0450367
0.2 - 1.0 bar (3 - 15 psig) ATO 0319678
0.2 - 1.0 bar (3 - 15 psig) ATC 1594842
0.4 - 1.0 bar (6 - 15 psig) ATO 0319678
0.4 - 1.0 bar (6 - 15 psig) ATC 1594842
1.5 - 2.4 bar (22 - 35 psig) ATO and ATC 1594842
2.0 - 3.2 bar (29 - 46 psig) ATO and ATC 1594842
Size GA 1.31, Travel 32 mm, ATO and ATC 0458112
Size GA 1.41, Travel 32 mm, ATO and ATC 0458112
With Side Mounted Handwheel
Size GA 1.21, Travel 16mm ATO and ATC 0319678
Size GA 1.31, Travel 16mm ATO and ATC 0319678
Size GA 1.31, Travel 32mm ATO and ATC 0458112

14 *Recommended spare parts

Instruction Manual
Form 5421
June 1999 Design 3024S Actuator

49A7913

Figure 12. Size-Mounted Handwheel for Type 3024S GA 1.21 and 1.31 Actuators.

Key Description Part Number

Side Mounted Handwheel (GA 1.21 &

1.31 only)
48 Body, steel 49A7900X012
49 Lever, steel 2317435
50 Operating Nut, brass 2317443
51 Drive Screw Assembly, steel/stainless steel
GA 1.21 29A7908X012
GA 1.31 29A7912X012
52 Pivot Pin, stainless steel 19A7914X012
53 Spacer, steel (2 required) 2317427
54 Shim Ring, steel 19A7918X012
55 Bushing (2 required) composite 19A7919X012
56 Retaining Ring, steel (2 required) 19A7920X012
57 Thrust Washer, composite 19A7921X012
58 Retaining Ring, steel 19A7923X012
59 Cap Screw, steel (2 required) 0262072
60 Hex Nut, steel (2 required) 19A7927X012
61 U−Bolt, steel (4 required) 19A7930X012
62 Hex Nut, steel (8 required) 19A4838X012
63 Lock, stainless steel 19A7931X012
64 Back Plate, steel (4 required) 10B1554X012
65 Hex Nut, steel 19A4788X012
--- Stem Connector Spacer 1Y45607E012

15
 Instruction Manual
Form 5421
Design 3024S Actuator June 1999

Fisher is a mark owned by Fisher Controls International, Inc., a business of Emerson Process Management. The Emerson logo is a
trademark and service mark of Emerson Electric Co. All other marks are the property of their respective owners.
The contents of this publication are presented for informational purposes only, and while every effort has been made to ensure their accuracy,
they are not to be construed as warranties or guarantees, express or implied, regarding the products or services described herein or their use
or applicability. We reserve the right to modify or improve the designs or specifications of such products at any time without notice.
Fisher does not assume responsibility for the selection, use or maintenance of any product. Responsibility for proper selection, use and
maintenance of any Fisher product remains solely with the purchaser.

Emerson Process Management

Fisher
Marshalltown, Iowa 50158 USA
Cernay 68700 France
Sao Paulo 05424 Brazil
Singapore 128461
www.Fisher.com

16
EFisher Controls International, Inc. 1999; All Rights Reserved